Scheduled maintenance becomes over-maintenance
Fixed-interval disassembly and inspection — the not-yet-broken gets disassembled, the already-broken gets missed. Wasted on both spare parts and labor.
Product Solution 02 / 08
Equipment Status Monitoring (Industrial/Electromechanical)
Motor, pump, compressor status acquisition — vibration + temperature + runtime — moving toward predictive maintenance
Solution Overview
Condition monitoring for electromechanical equipment such as pumps, compressors, and motors. Collects operational parameters, AI identifies early fault characteristics, enabling predictive maintenance and reducing equipment repair costs.
Pump rooms and water supply/drainageCompressor stationsVentilation and dust removal fansCooling towers and utilitiesMachining workshop main equipment
Problems Solved
Auxiliary equipment unattended
Pump rooms, compressor stations, and power distribution rooms typically have no fixed attendants. Anomalies are only discovered when alarms trigger.
Fault patterns cannot be accumulated
Without continuous vibration and temperature data, fault modes cannot be correlated with maintenance actions.
Traditional Solution vs ZHIYUAN AIoT
TraditionalZHIYUAN AIoT
Alert MethodFixed threshold alerts: only fire at limit crossings, blind to slow degradation. A single fault floods dozens of useless alerts, burying real risks.AI time-series anomaly detection: learns each device's baseline, catches slow drift and hidden anomalies. 80% fewer false alarms, alerts routed to the right people.
Notification & ClosurePhone calls/group chat: alerts dumped in chat, who handles what? Night alerts buried, discovered next day.WeCom/SMS graded push + work order automation: graded, person-specific routing. Unacknowledged alerts auto-escalate. Full traceability: alert → work order → resolution → archive.
Integration & RetrofittingCostly retrofit & downtime: new monitoring needs rewiring, equipment swap, production stoppage — long cycle, lost output.Reuse existing sensors, plug & go live: compatible with 95% DTUs/sensors. MQTT/Modbus standard protocols. No production line changes — 30-minute data integration.
Data ValueReal-time only, no history: manual logs capture instant values only — no trend visibility, can't replay fault evolution.Time-series database + history replay: massive long-term storage, any-range curve playback with work order records to reconstruct full fault picture and continuously improve O&M strategy.
Key Features
Unified multi-type electromechanical equipment management
Motor, pump, fan, compressor — each type has its own monitoring template and baseline.
Combined vibration and temperature analysis
Synchronously observe vibration severity and temperature rise; when both deteriorate in the same direction, alert level escalates.
Runtime and start-stop statistics
Record cumulative runtime and start-stop frequency; identify frequent start-stop and idle running.
Early fault characteristic identification
Learn normal characteristics from historical curves; flag degradation warnings for deviating trends.
Maintenance recommendation trail
Degradation warnings convert to work orders; repair results written back to equipment file — one file per machine.
Data Collection & Alerting Specs
Collected Data
- Vibration severity
- Bearing/housing temperature
- Operational status and start-stop count
- Cumulative runtime
- Current and pressure (per field signal)
Alert Types
- Vibration trend rising
- Abnormal temperature rise
- Frequent start-stop
- Prolonged idle
- Device offline
- Degradation warning
Alerts pushed to Web dashboard and WeCom; SMS as optional add-on. Same-type alerts auto-merged for noise reduction.
Deployment & Billing
- Deployment
- Prioritize reusing existing transmitter signals on site; where no signal exists, add wireless (no-wiring) vibration-temperature sensors, battery-powered, no modification to control cabinets.
- Billing
- Subscription by device count, including sensor selection guidance and point configuration services.
FAQ
How far in advance can predictive maintenance detect a fault?
Depends on the fault type. Gradual degradation faults like bearing wear, misalignment, and poor lubrication typically show observable deterioration trends and can give early warnings. Sudden fracture-type faults cannot be predicted, so the system must still be used alongside routine inspections.
Are wireless sensors reliable?
Industrial-grade low-power wireless solution is used. Battery life is evaluated based on reporting frequency and explained during selection. The platform simultaneously monitors sensor battery level and signal strength; low battery triggers a separate reminder — no unmanaged blind spots.
Related Solutions
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